Polaris RZR 900 2015 - User Manual

FOREWORD
The information printed within this publication includes the latest product information at time of print. The most recent
version of this Service Manual is available in electronic format at www.polarisdealers.com.
This Service Manual is designed primarily for use by certified Polaris Master Service Dealer
®
technicians in a properly
equipped shop and should be kept available for reference. All references to left and right side of the vehicle are from
the operator's perspective when seated in a normal riding position.
Some procedures outlined in this manual require a sound knowledge of mechanical theory, tool use, and shop
procedures in order to perform the work safely and correctly. Technicians should read the text and be familiar with the
service procedures before starting any repair. Certain procedures require the use of special tools. Use only the proper
tools as specified. If you have any doubt as to your ability to perform any of the procedures outlined in this Service
Manual, contact an authorized dealer for service.
We value your input and appreciate any assistance you can provide in helping make these publications more useful.
Please provide any feedback you may have regarding this manual. Authorized dealers can submit feedback using 'Ask
Polaris'. Click on 'Ask Polaris', and then click on 'Service Manual / Service Literature Question'.
Consumers, please provide your feedback in writing to: Polaris Industries Inc. ATTN: Service Publications Department,
2100 Hwy 55, Medina, MN 55340.
Publication Printed September 2015 (PN 9926814 R08)
© Copyright 2017 Polaris Industries Inc. All information contained within this publication is based on the latest product information at the time of publication. Due to
constant improvements in the design and quality of production components, some minor discrepancies may result between the actual vehicle and the information
presented in this publication. Depictions and/or procedures in this publication are intended for reference use only. No liability can be accepted for omissions or
inaccuracies. Any reprinting or reuse of the depictions and/or procedures contained within, whether whole or in part, is expressly prohibited. Printed in U.S.A.
2015-2016 RZR 900
2016 RZR S 1000

Polaris RZR 900 2015 Specifications

General

Brand	Polaris
Model	RZR 900 2015
Category	Offroad Vehicle
Language	English

Summary

Foreword

Safety Warnings

Trademarks

Chapter 1: General Information

Chapter Summary

Provides a summary of the chapters included in the manual.

Vehicle Identification

Details on identifying vehicle model number and VIN designation.

Vehicle and Engine Serial Number Location

Information on finding vehicle and engine serial numbers.

Misc. Information

Covers publication numbers, replacement keys, and special tools.

General Specifications

Detailed specifications for various RZR models and years.

Misc. Specifications and Charts

Includes master torque table, conversion table, and tap/drill sizes.

Chapter 2: Maintenance

Periodic Maintenance Chart

Outline of periodic maintenance tasks and intervals.

Maintenance Intervals

Table detailing maintenance intervals in hours, calendar, and miles.

General Vehicle Inspection and Maintenance

Procedures for general vehicle inspection and maintenance.

Pre-Ride; Daily Inspection

Daily inspection checklist for vehicle safety and operation.

Engine; Air Intake

Procedures related to engine air intake system maintenance.

Engine Oil Level

Procedure for checking the engine oil level.

Engine Oil and Filter Change

Step-by-step guide for changing engine oil and filter.

Valve Clearance Inspection

Procedure for inspecting valve clearances.

Cooling System

Information and procedures for maintaining the engine cooling system.

Fuel System

Information and procedures for the vehicle's fuel system.

PVT System

Procedures related to the Primary Variable Transmission (PVT) system.

Driveshaft; Wheel and Tire

Procedures for inspecting and servicing driveshafts, wheels, and tires.

Transmission and Front Gearcase

Specifications and procedures for transmission and front gearcase maintenance.

Chapter 8: Steering; Suspension

Steering System

General information, replacement, and inspection procedures for the steering system.

Front Suspension

Assembly views and replacement procedures for front suspension components.

Rear Suspension

Procedures for removal and installation of rear suspension components.

Shocks; Springs

Assembly views, service, and specifications for shock absorbers and springs.

Chapter 9: Brake System

Brake System Service Notes

Important notes and tips for servicing the brake system.

Hydraulic Brake System Operation

Explanation of how the hydraulic brake system components function.

Master Cylinder

Procedures for removing and installing the master cylinder.

Brake Pedal

Procedures for removing and installing the brake pedal lever.

Brake Bleeding; Fluid Change

Procedure for bleeding the brake system and changing the fluid.

Parking Brake (INTL)

Information and procedures specific to the international model parking brake.

Front Brakes

Procedures for front brake caliper and pad service.

Rear Brakes

Procedures for rear brake caliper and pad service.

Troubleshooting

Diagnostic information for common brake system issues.

Chapter 10: Body; Frame

Decal Replacement

Procedure for replacing decals using flame treatment.

Body Assembly Views

Diagrams illustrating various body component assemblies.

Chassis; Main Frame

Components and fasteners related to the main chassis frame.

Seats

Procedures for removing and installing front and rear seats.

Floor; Rocker Panels

Procedures for removing and installing floor and rocker panel components.

Doors

Procedures for door panel, latch replacement, and adjustment.

Chapter 11: Electrical

Instrument Cluster

Overview, display area, diagnostic mode, and pinouts for the instrument cluster.

Switches

Testing and replacement procedures for various vehicle switches.

Charging System

Information and tests for the stator and voltage regulator.

Battery

Procedures for battery removal, installation, and testing.

Lighting System

Procedures for headlight, taillight, and dash LED replacement and adjustment.

Starting System

Troubleshooting, removal, and installation procedures for the starter system.

Electronic Power Steering

Overview, diagnostics, and procedures for the EPS system.

Fuses; Relays

Information on fuse box layout and relay circuits.